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Step-By-Step Sash Construction

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Step-By-Step Sash Construction Step-by-step window ® sash construction 1 In this step by step example for window sash GLASS 1/8" glass RAIL STILE DETAIL construction, we used the following: STOP DETAIL Stock removed in Step 10 • CMT Window Sash Set (Item No. 855.801.11) DETAIL • stile cut 1-3/8” thick Quarter round • rail cut 1-3/8” thick (1/4 x 1/4" 1/4" mortise glass stop) • scrap stock Face side Back of Finish nail stile 1/4" tenon The CMT Window Sash Set was designed ideally Face side for the construction of windows in 1-3/8” stock, Coping Cut however, variations as narrow as 1-7/64” can be used. Stock thicker than 1-3/8” exceeds the milling 1 3/8" -thick stock STILE range of the cutter. Remember to adjust your measurements and cutting depths according to the RAIL wood thickness you use. We suggest making a trial 1/4"-thick tenons 1 1/4" long joint in scrap stock according to the following steps Cuts made with profile bit before milling all of the cope and stick profiles. 1/4"-wide mortise 1 5/8" deep Miter corners SASH STEP 1 BAR Cut your stiles, rails, sash bars, and muntins to the width and length from 1-3/8” thick stock. Here’s MUNTINS how to calculate the lengths of your parts, using an 18x24 window with 3” wide rails and stiles as an example. 1/4" X 3/4" mortise 1 5/8" deep First, cut the stiles to the full height of the window 1/4"-thick tenon GLASS (24”). To figure rail length, subtract the combined 1/8" long width of the stiles (6”) from the finished width of the window (18”). To this number (12”), add the length RAIL Quarter-round of two tenons (1-1/4” + 1-1/4”) and 1/2” (for the glass stops Face side coped joint). So, for our example we cut the rails 15” long. Cut the sash bars and muntins 3/4” wide and calculate their lengths as you did the rails. (Plan STILE to cut 1-1/4” long tenons on both ends of the sash bar and muntins; you’ll trim the muntin tenons that intersect with the sash bars to 1/8” long later.) STEP 2 Mark the face side of your workpieces (the inside your tablesaw and adjust it for a 5/8” high cut. Position the surface or your window or the most-viewed side of saw’s fence 1-1/4” from the side of the dado set farthest your door). Also, mark the outside edges of the rails from the fence. Place the workpiece on the tablesaw face and stiles, and place marks centered on the rails down with one edge against a miter gauge, and one end and stiles where they against the fence. Make the cut in multiple passes . intersect with the MITER GAUGE STEP 4 muntins and sash bar, ADJUST DADO FOR A FENCE MITER GA UGE and on the sash bar 5/8" HIGH CUT Position the rail, sash bar, or where it intersects muntin face side up on the FACE SIDE UP with the muntins. FENCE tablesaw. Place a 1/8” spacer between the TENON STEP 3 SHOULDER workpiece and tablesaw top INSIDE FACE OF and make the same cut as To cut 1-1/4” tenons WORK PIECE DOWN described in the previous on both ends of the 1/8" THICK SPACER rails, sash bars, and step. Your tenons should be ADJUST FENCE TO OUTSIDE OF DADO 1/4” thick. muntins, install a full- SET DISTANCE TO MATCH LENGTH OF TENON. width dado set in Step-by-step window ® sash construction 2 STEP 5 Complete the tenon cuts on the rails by placing them outside edge down on the tablesaw. Make multiple cuts with the dado set 5/8” high as before. STEP 6 OUTSIDE EDGE OF Install the coping bit in your WINDOW DOWN router table. Place the face side of the rail on the table and STEP 10 adjust the coping bit up so the Mold both edges of the tops of its cutters contact the sash bar and muntins. tenon. With the fence adjusted so the coping bit cuts 1/4” Use pushsticks to pass past the tenon shoulder, cut both ends of the rails, sash the stock between the bar, and muntins. (For a 1-1/4” long tenon, set the fence fences. 1-1/2” from the cutter tip with the tip rotated to its farthest distance from the fence.) Use a fine-toothed saw to remove the small STEP 7 amount of material on Mark the positions of the the outside end of each mortises on the stiles by using stile mortise and in the the tenon that mates with it. Stile Detail drawing on First, stand the stile inside edge page 12. If you make up on a work surface and more than one window position the rail to mark the or door you may want to set up a router table with a length of the mortise. Then, rest straight bit to do this more quickly. the rail on top of the stile to mark the mortise width. Use the same Now’s a good time to trim the muntin tenons that steps to mark the position of the intersect the sash bar. Cut them to 1/8” long. mortises that hold the sash bar and muntin tenons. STEP 11 Assemble the project without glue to check it for fit Cut the mortises 3/8” deeper than the length of the and squareness. Disassemble, apply glue to all mating tenons. The mortise in the sash bar will go completely surfaces and clamp. through it. Check for square again before the glue sets up. STEP 8 STEP 12 RAIL Install the profile bit in your router table and adjust it. Install the glass in the With the face side down, rabbeted openings on mold the inside edges of the the back face of the door rails and stiles. or window. Each pane HOLD FLUSH HERE should be 1/8” smaller in STEP 9 width and length than the To perform the same rabbeted opening it fits STILE operation on the sash bar into. Mount the glass in and muntins, clamp a place with glazing points secondary fence onto the and glazing putty, or with quarter-round strips of router table. Make this fence wood mitered on their ends and nailed down. from 1-1/4” thick stock, and ® position it so the sash bar and muntins slide snugly Window Sash instructions courtesy of WOOD Magazine For Subscriptions-call 1-800-374-9663 or visit between it and the main fence. WOOD® online at www.woodmagazine.com.
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